Mechanical fastening system for an absorbent article

ABSTRACT

An absorbent article such as infant training pants is provided with a mechanical hook-and-loop type fastening system utilizing multi-directional stretchable nonwoven materials that function well with low shear strength.

BACKGROUND OF THE INVENTION

The present invention pertains to absorbent articles, such as training pants, diapers, incontinence garments and the like, and more particularly, to a mechanical fastening system for such absorbent articles.

Such absorbent articles generally comprise a liquid-impermeable barrier sheet, a liquid permeable body side liner and an absorbent medium between them. They generally include some type of attaching system for fitting the article to the wearer. In many such applications, the fastening system is preferably refastenable so that the article can be temporarily removed and then refastened to the wearer.

Common forms of mechanical attachment systems are the so called hook-and-loop systems which come in various forms and has both advantages and disadvantages in their application to such absorbent articles. For example, particularly with diapers, the fasteners are secured to both sides of the garment on the front and back thereof, generally in such a manner that the back portion of the fasteners on each side are pulled over the front portion to secure the garment to the wearer. In typical such products, the loop material is generally non-extensible and is attached to the surface of the garment. The hook material is generally attached to an extensible substrate so that it can be positioned on the loop material for adjustment to the size and shape of the wearer of the garment.

A disadvantage of this type of hook-and-loop system is the tendency of the hooks to separate from the loop material when the wearer is active, such as when stooping or bending as is common with a child. This disengagement failure results in the garment coming loose from the wearer (with possible leakage resulting) thus requiring it to be refastened, if possible. This produces an undesirable inconvenience and disadvantage of such a mechanical fastening system for such applications. In an attempt to overcome this disadvantage many systems have increased the force to disengage through various enhancements in strengthening the hook-and-loop material.

SUMMARY OF THE INVENTION

The present invention overcomes the above-described difficulties and disadvantages associated with such prior art mechanical fastening systems by providing a hook-and-loop fastening system in which the loop material is a multi-directional stretchable material. This multi-directional loop system on a product can reduce stress on the fastening system to allow products with low shear strengths to perform as well as products with high shear strengths using loop materials that do not stretch. Products with fastening systems like this provide a significant advantage for products like disposable diapers or disposable training pants or the like.

One aspect of the invention pertains to a garment for personal wear. In particular embodiments, a garment for personal wear comprises: a body having first and second end regions; a mechanical fastening system disposed on the body, the mechanical fastening system comprising: a multi-directional stretchable landing member disposed in the first end region and comprising a multi-directional stretchable loop material, the multi-directional stretchable loop material being extensible during use in first and second substantially perpendicular directions and being elastomeric during use in at least one of the first and second directions, and a closure member disposed in the second end region and comprising a hook material adapted to refastenably engage the multi-directional stretchable loop material; wherein the multi-directional stretchable landing member and closure member provide shear strength values of less than 3900 grams in each of the first and second directions.

The term “multi-directional stretchable loop material” as used herein refers to a material having fibers available to engage hooks and the material as incorporated into the product is extensible in at least first and second directions which are substantially perpendicular. The loop material as incorporated into the product can additionally be elastomeric in one or both of the first and second directions. In particular embodiments, for example, the first and second directions can coincide with the longitudinal and transverse axes of the product. For instance, the multi-directional stretchable loop material can be disposed within the product so as to be extensible in the longitudinal and transverse directions and elastomeric in the transverse direction. Other orientations may be desirable in other products.

Another aspect of the invention pertains to a disposable absorbent article for personal wear. In one embodiment, a disposable absorbent article comprises: a body having first and second end regions and comprising a liquid permeable inner layer, an outer layer in opposed relation with the inner layer, and an absorbent layer disposed between the inner layer and the outer layer; a mechanical fastening system disposed on the body, the mechanical fastening system comprising: a multi-directional stretchable landing member disposed in the first end region and comprising a multi-directional stretchable loop material, the multi-directional stretchable loop material being extensible during use in first and second substantially perpendicular directions and being elastomeric during use in at least one of the first and second directions, and a closure member disposed in the second end region and comprising a hook material adapted to refastenably engage the multi-directional stretchable loop material; wherein the multi-directional stretchable landing member and closure member provide shear strength values of about 1500 to about 3500 grams in each of the first and second directions.

In another embodiment, a disposable absorbent article comprises: a body having first and second end regions and comprising a liquid permeable inner layer, an outer layer in opposed relation with the inner layer, and an absorbent layer disposed between the inner layer and the outer layer; a mechanical fastening system disposed on the body, the mechanical fastening system comprising: a multi-directional stretchable landing member disposed in the first end region and comprising a multi-directional stretchable loop material, the multi-directional stretchable loop material being extensible and elastomeric during use in first and second substantially perpendicular directions, and a closure member disposed in the second end region and comprising a hook material adapted to refastenably engage the multi-directional stretchable loop material; wherein the multi-directional stretchable landing member and closure member provide shear strength values of about 1500 to about 3500 grams in each of the first and second directions.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features of the present invention, and the manner of obtaining them, will become more apparent and the invention itself will be better understood by reference to the following description of the embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

FIG. 1 illustrates a side view of a training pant according to the present invention, where the fastening system is shown engaged on one side of the training pant and disengaged on the other side of the training pant.

FIG. 2 illustrates a plan view of the training pant shown in FIG. 1 in an unfastened, stretched and laid flat condition, and showing the surface of the training pant that faces away from the wearer.

FIG. 3 illustrates a plan view similar to FIG. 2, but showing the surface of the training pant that faces the wearer when the training pant is worn, and with portions cut away to show the underlying features.

FIG. 4 illustrates an alternative embodiment of the present invention in a side view similar to FIG. 1.

FIG. 5 is a plan view of the embodiment of FIG. 4 in a similar position as FIG. 3.

Corresponding reference characters indicate corresponding parts throughout the drawings.

DEFINITIONS

Within the context of this specification, each term or phrase below will include the following meaning or meanings.

“Bonded” refers to the joining, adhering, connecting, attaching, or the like, of two elements. Two elements will be considered to be bonded together when they are bonded directly to one another or indirectly to one another, such as when each is directly bonded to intermediate elements.

“Comprising” is inclusive or open-ended and does not exclude additional, unrecited elements or method steps.

“Connected” refers to the joining, adhering, bonding, attaching, or the like, of two elements. Two elements will be considered to be connected together when they are connected directly to one another or indirectly to one another, such as when each is directly connected to intermediate elements.

“Disposable” refers to articles which are designed to be discarded after a limited use rather than being laundered or otherwise restored for reuse.

“Disposed,” “disposed on,” and variations thereof are intended to mean that one element can be integral with another element, or that one element can be a separate structure bonded to or placed with or placed near another element.

“Elastic,” “elasticized” and “elasticity” mean that property of a material or composite by virtue of which it tends to recover its original size and shape after removal of a force causing a deformation.

“Elastomeric” refers to a material or composite which can be elongated by at least 25 percent of its relaxed length and which will recover, upon release of the applied force, at least 10 percent of its elongation. It is generally preferred that the elastomeric material or composite be capable of being elongated by at least 100 percent, more preferably by at least 300 percent, of its relaxed length and recover, upon release of an applied force, at least 50 percent of its elongation.

“Extensible” refers to a material or composite that is stretchable or capable of being elongated in at least one direction, but which may not have sufficient recovery to be considered elastic.

“Fabrics” is used to refer to all of the woven, knitted and nonwoven fibrous webs.

“Flexible” refers to materials which are compliant and which will readily conform to the general shape and contours of the wearer's body.

“Force” includes a physical influence exerted by one body on another which produces acceleration of bodies that are free to move and deformation of bodies that are not free to move.

“Graphic” refers to any design, pattern, or the like that is visible on an absorbent article.

“Hydrophilic” describes fibers or the surfaces of fibers which are wetted by the aqueous liquids in contact with the fibers. The degree of wetting of the materials can, in turn, be described in terms of the contact angles and the surface tensions of the liquids and materials involved. Equipment and techniques suitable for measuring the wettability of particular fiber materials or blends of fiber materials can be provided by a Cahn SFA-222 Surface Force Analyzer System, or a substantially equivalent system. When measured with this system, fibers having contact angles less than 90 are designated “wettable” or hydrophilic, while fibers having contact angles greater than 90 are designated “nonwettable” or hydrophobic.

“Integral” is used to refer to various portions of a single unitary element rather than separate structures bonded to or placed with or placed near one another.

“Inward” and “outward” refer to positions relative to the center of an absorbent article, and particularly transversely and/or longitudinally closer to or away from the longitudinal and transverse center of the absorbent article.

“Layer” when used in the singular can have the dual meaning of a single element or a plurality of elements.

“Liquid impermeable”, when used in describing a layer or multi-layer laminate, means that a liquid, such as urine, will not pass through the layer or laminate, under ordinary use conditions, in a direction generally perpendicular to the plane of the layer or laminate at the point of liquid contact. Liquid, or urine, may spread or be transported parallel to the plane of the liquid impermeable layer or laminate, but this is not considered to be within the meaning of “liquid impermeable” when used herein.

“Longitudinal” and “transverse” have their customary meaning, as indicated by the longitudinal and transverse axes depicted in FIGS. 2 and 3. The longitudinal axis lies in the plane of the article and is generally parallel to a vertical plane that bisects a standing wearer into left and right body halves when the article is worn. The transverse axis lies in the plane of the article generally perpendicular to the longitudinal axis. The article as illustrated is longer in the longitudinal direction than in the transverse direction.

“Member” when used in the singular can have the dual meaning of a single element or a plurality of elements.

“Nonwoven” and “nonwoven web” refer to materials and webs of material which are formed without the aid of a textile weaving or knitting process.

“Operatively joined,” with reference to the attachment of an elastic member to another element, means that the elastic member when attached to or connected to the element, or treated with heat or chemicals, by stretching, or the like, gives the element elastic properties; and with reference to the attachment of a non-elastic member to another element, means that the member and element can be attached in any suitable manner that permits or allows them to perform the intended or described function of the joinder. The joining, attaching, connecting or the like can be either directly, such as joining either member directly to an element, or can be indirectly by means of another member disposed between the first member and the first element.

“Outer cover graphic” refers to a graphic that is directly visible upon inspection of the exterior surface of a garment, and for a refastenable garment is in reference to inspection of the exterior surface of the garment when the fastening system is engaged as it would be during use.

“Permanently bonded” refers to the joining, adhering, connecting, attaching, or the like, of two elements of an absorbent garment such that the elements tend to be and remain bonded during normal use conditions of the absorbent garment.

“Refastenable” refers to the property of two elements being capable of attachment, separation, and subsequent reattachment.

“Releasably attached,” “releasably engaged” and variations thereof refer to two elements being connected or connectable such that the elements tend to remain connected absent a separation force applied to one or both of the elements, and the elements being capable of separation without substantial permanent deformation or rupture. The required separation force is typically beyond that encountered while wearing the absorbent garment.

“Necking” or “neck stretching” interchangeably refer to a method of elongating a material, generally in the machine direction, to reduce its width in a controlled manner to a desired degree. The controlled stretching may take place under cool conditions, at room temperature, or at an elevated temperature, and is limited to an increase in overall dimension in the direction of elongation up to the elongation required to break the fabric, which in most cases is about 1.2 to 1.4 times the original fabric length.

“Creping” and “creped” refer to a method of gathering a material in the machine direction to allow it some extensibility in that direction, which typically is accompanied by a reduction in the length of the material.

“Oriented material” refers to a material in which mechanical drawing of the material has resulted in alignment of the fibers constituting the material in a direction generally parallel to the direction of the applied force.

“Reversibly necked material” refers to a necked material that has been treated while necked to impart memory to the material so that, when a force is applied to extend the material to its pre-necked dimensions, the necked and treated portions will generally recover to their necked dimensions upon termination of the force. One form of treatment is the application of heat. Generally speaking, extension of the reversibly necked material is substantially limited to extension to its pre-necked dimensions. Therefore, unless the material is elastic, extension too far beyond its pre-necked dimensions will result in material failure. A reversibly necked material may include more than one layer. For example, multiple layers of spunbonded web, multiple layers of meltblown web, multiple layers of bonded carded web or any other suitable combination or mixtures thereof.

“Rupture” means the breaking or tearing apart of a material; in tensile testing, the term refers to the total separation of a material into two parts either all at once or in stages, or the development of a hole in some materials.

“Stretch bonded” refers to an elastic member being bonded to another member while the elastic member is extended at least about 25 percent of its relaxed length. Desirably, the term “stretch bonded” refers to the situation wherein the elastic member is extended at least about 100 percent, and more desirably at least about 300-600 percent, of its relaxed length when it is bonded to the other member.

“Stretch bonded laminate” refers to a composite material having at least two layers in which one layer is a gatherable layer and the other layer is an elastic layer. The layers are joined together when the elastic layer is in an extended condition so that upon relaxing the layers, the gatherable layer is gathered.

“Surface” includes any layer, film, woven, nonwoven, laminate, composite, or the like, whether pervious or impervious to air, gas, and/or liquids.

“Tension” includes a uniaxial force tending to cause the extension of a body or the balancing force within that body resisting the extension.

“Thermoplastic” describes a material that softens when exposed to heat and which substantially returns to a non-softened condition when cooled to room temperature.

These terms may be defined with additional language in the remaining portions of the specification.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 representatively illustrates one embodiment of training pant 20 in a partially fastened condition. The training pant 20 comprises an absorbent body 32 and a fastening system 80. The absorbent body 32 defines a front waist region 22, a back waist region 24, a crotch region 26 interconnecting the front and back waist regions, an inner surface 28 which is configured to contact the wearer, and an outer surface 30 opposite the inner surface which is configured to contact the wearer's clothing. With additional reference to FIGS. 2 and 3, the absorbent body 32 also defines a pair of transversely opposed side edges 36 and a pair of longitudinally opposed waist edges, which are designated front waist edge 38 and back waist edge 39. The front waist region 22 is contiguous with the front waist edge 38, and the back waist region 24 is contiguous with the back waist edge 39.

The illustrated absorbent body 32 comprises a rectangular composite structure 33, a pair of transversely opposed front side panels 34, and a pair of transversely opposed back side panels 134. The composite structure 33 and side panels 34 and 134 may be integrally formed or comprise two or more separate elements, as shown in FIG. 1. The illustrated composite structure 33 comprises an outer cover 40, a body side liner 42 (FIG. 3) which is connected to the outer cover in a superposed relation, an absorbent assembly 44 (FIG. 3) which is located between the outer cover and the body side liner, and a pair of containment flaps 46 (FIG. 3). The illustrated composite structure 33 has opposite linear end edges 45 that form portions of the front and back waist edges 38 and 39, and opposite linear side edges 47 that form portions of the side edges 36 of the absorbent body 32 (FIGS. 2 and 3). For reference, arrows 48 and 49 depicting the orientation of the longitudinal axis and the transverse axis, respectively, of the training pant 20 are illustrated in FIGS. 2 and 3.

With the training pant 20 in the fastened position as partially illustrated in FIG. 1, the front and back waist regions 22 and 24 are joined together to define a three-dimensional pant configuration having a waist opening 50 and a pair of leg openings 52. The front waist region 22 comprises the portion of the training pant 20 which, when worn, is positioned on the front of the wearer while the back waist region 24 comprises the portion of the training pant which, when worn, is positioned on the back of the wearer. The crotch region 26 of the training pant 20 comprises the portion of the training pant which, when worn, is positioned between the legs of the wearer and covers the lower torso of the wearer. The front and back side panels 34 and 134 comprise the portions of the training pant 20 which, when worn, are positioned on the hips of the wearer.

The front waist region 22 of the absorbent body 32 includes the transversely opposed front side panels 34 and a front center panel 35 (FIGS. 2 and 3) positioned between and interconnecting the side panels. The back waist region 24 of the absorbent body 32 includes the transversely opposed back side panels 134 and a back center panel 135 (FIGS. 2 and 3) positioned between and interconnecting the side panels. The waist edges 38 and 39 of the absorbent body 32 are configured to encircle the waist of the wearer when worn and provide the waist opening 50 which defines a waist perimeter dimension. Portions of the transversely opposed side edges 36 in the crotch region 26 generally define the leg openings 52. The waist regions 22 and 24 jointly define a waistband 75 (FIGS. 1 and 4) that peripherally surrounds the waist opening 50 of the pant 20. The waist regions 22 and 24 also jointly define a hip section 77 (FIGS. 1 and 4) that encircles the pant 20 and is disposed between the waistband 75 and the leg openings 52.

The absorbent body 32 is configured to contain and/or absorb any body exudates discharged from the wearer. For example, the absorbent body 32 desirably although not necessarily comprises the pair of containment flaps 46 which are configured to provide a barrier to the transverse flow of body exudates. A flap elastic member 53 (FIG. 3) is operatively joined with each containment flap 46 in any suitable manner as is well known in the art. The elasticized containment flaps 46 define an unattached edge which assumes an upright configuration in at least the crotch region 26 of the training pant 20 to form a seal against the wearer's body. The containment flaps 46 can be located along the transversely opposed side edges of the absorbent body 32, and can extend longitudinally along the entire length of the absorbent body or may only extend partially along the length of the absorbent body. Suitable constructions and arrangements for the containment flaps 46 are generally well known to those skilled in the art and are described in U.S. Pat. No. 4,704,116 issued Nov. 3, 1987 to Enloe, which is incorporated herein by reference.

To further enhance containment and/or absorption of body exudates, the training pant 20 desirably although not necessarily includes a front waist elastic member 54, a rear waist elastic member 56, and leg elastic members 58, as are known to those skilled in the art (FIG. 3). The waist elastic members 54 and 56 can be operatively joined to the outer cover 40 and/or body side liner 42 along the opposite waist edges 38 and 39, and can extend over part or all of the waist edges, such that the waist elastic members are disposed in the waistband 75 in the fully assembled pant.

The leg elastic members 58 are desirably operatively joined to the outer cover 40 and/or body side liner 42 along the opposite side edges 36 and positioned in the crotch region 26 of the training pant 20. The leg elastic members 58 can be longitudinally aligned along each side edge 47 of the composite structure 33. Each leg elastic member 58 has a front terminal point 63 and a back terminal point 65, which points represent the longitudinal ends of the elastic gathering caused by the leg elastic members. The front terminal points 63 can be located adjacent the longitudinally innermost parts of the front side panels 34, and the back terminal points 65 can be located adjacent the longitudinally innermost parts of the back side panels 134.

The flap elastic members 53, the waist elastic members 54 and 56, and the leg elastic members 58 can be formed of any suitable elastic material. As is well known to those skilled in the art, suitable elastic materials include sheets, strands or ribbons of natural rubber, synthetic rubber, or thermoplastic elastomeric polymers. The elastic materials can be stretched and adhered to a substrate, adhered to a gathered substrate, or adhered to a substrate and then elasticized or shrunk, for example with the application of heat; such that elastic constrictive forces are imparted to the substrate. In one particular embodiment, for example, the leg elastic members 58 comprise a plurality of dry-spun coalesced multifilament spandex elastomeric threads sold under the trade name LYCRA and available from E. I. DuPont de Nemours and Company, Wilmington, Del. U.S.A.

In particular embodiments, the waist elastic members 54 and 56 can be formed of retractive materials. For example, the waist elastic members 54 and 56 can be formed of an elastomeric material that is adapted to retract upon activation by a source of heat such as disclosed in U.S. Pat. No. 4,640,726.

The outer cover 40 desirably comprises a material that is substantially liquid impermeable, and can be elastic or inelastic. The outer cover 40 can be a single layer of liquid impermeable material, but desirably comprises a multi-layered laminate structure in which at least one of the layers is liquid impermeable. For instance, the outer cover 40 can include a liquid permeable outer layer and a liquid impermeable inner layer that are suitably joined together by laminate adhesive, ultrasonic bonds, thermal bonds, or the like. Suitable laminate adhesives, which can be applied continuously or intermittently as beads, a spray, parallel swirls, or the like, can be obtained from Findley Adhesives, Inc., of Wauwatosa, Wis. U.S.A., or from National Starch and Chemical Company, Bridgewater, N.J. U.S.A. The liquid permeable outer layer can be any suitable material and desirably one that provides a generally cloth-like texture. One example of such a material is a 20 gsm (grams per square meter) spunbond polypropylene nonwoven web. While it is not a necessity for the outer layer to be liquid permeable, it is desired that it provides a relatively cloth-like texture to the wearer The outer cover may also be made of a multi-directional stretchable material made with a nonwoven facing and an elastic base material as provided by this invention, constituting an integral and functional loop material as the entire outer surface of the cover 40.

The inner layer of the outer cover 40 can be both liquid and vapor impermeable, or can be liquid impermeable and vapor permeable. The inner layer is desirably manufactured from a thin plastic film, although other flexible liquid impermeable materials may also be used. The inner layer, or the liquid impermeable outer cover 40 when a single layer, prevents waste material from wetting articles, such as bed sheets and clothing, as well as the wearer and caregiver. A suitable liquid impermeable film for use as a liquid impermeable inner layer, or a single layer liquid impermeable outer cover 40, is a 0.02 millimeter polyethylene film commercially available from Huntsman Packaging of Newport News, Va. U.S.A. If the outer cover 40 is a single layer of material, it can be embossed and/or matte finished, providing a more cloth-like appearance. As earlier mentioned, the liquid impermeable material can permit vapors to escape from the interior of the disposable absorbent article, while still preventing liquids from passing through the outer cover 40. A suitable “breathable” material is composed of a microporous polymer film or a nonwoven fabric that has been coated or otherwise treated to impart a desired level of liquid impermeability. A suitable microporous film is a PMP-1 film material commercially available from Mitsui Toatsu Chemicals, Inc., Tokyo, Japan, or an XKO-8044 polyolefin film commercially available from 3M Company, Minneapolis, Minn. U.S.A.

As shown in FIGS. 1 and 2, the training pant 20 and in particular the outer cover 40 desirably comprises one or more appearance-related components. Examples of appearance-related components include, but are not limited to, graphics; highlighting or emphasizing leg and waist openings in order to make product shaping more evident or visible to the user; highlighting or emphasizing areas of the product to simulate functional components such as elastic leg bands, elastic waistbands, simulated fly openings for boys, ruffles for girls; highlighting areas of the product to change the appearance of the size of the product; registering wetness indicators, temperature indicators, and the like in the product; registering a back label, or a front label, in the product; and registering written instructions at a desired location in the product.

The illustrated training pant 20, which is designed for use by young girls, includes a registered outer cover graphic 60. In this design, the registered graphic 60 includes a primary pictorial image 61, simulated waist ruffles 62, and simulated leg ruffles 64. The primary pictorial image 61 includes a rainbow, sun, clouds, animal characters, wagon and balloons. Any suitable design can be utilized for a training pant intended for use by young girls, so as to be aesthetically and/or functionally pleasing to them and the caregiver. The appearance-related components are desirably positioned on the training pant 20 at selected locations, which can be carried out using the methods disclosed in U.S. Pat. No. 5,766,389 issued Jun. 16, 1998 to Brandon et al., which is incorporated herein by reference. The primary pictorial image 61 is desirably positioned in the front waist region 22 along the longitudinal centerline of the training pant 20.

The liquid permeable body side liner 42 is illustrated as overlying the outer cover 40 and absorbent assembly 44, and may but need not have the same dimensions as the outer cover 40. The body side liner 42 is desirably compliant, soft feeling, and non-irritating to the child's skin. Further, the body side liner 42 can be less hydrophilic than the absorbent assembly 44, to present a relatively dry surface to the wearer and permit liquid to readily penetrate through its thickness. Alternatively, the body side liner 42 can be more hydrophilic or can have essentially the same affinity for moisture as the absorbent assembly 44 to present a relatively wet surface to the wearer to increase the sensation of being wet. This wet sensation can be useful as a training aid. The hydrophilic/hydrophobic properties can be varied across the length, width and depth of the body side liner 42 and absorbent assembly 44 to achieve the desired wetness sensation or leakage performance.

The body side liner 42 can be manufactured from a wide selection of web materials, such as synthetic fibers (for example, polyester or polypropylene fibers), natural fibers (for example, wood or cotton fibers), a combination of natural and synthetic fibers, porous foams, reticulated foams, apertured plastic films, or the like. Various woven and nonwoven fabrics can be used for the body side liner 42. For example, the body side liner can be composed of a meltblown or spunbonded web of polyolefin fibers. The body side liner can also be a bonded-carded web composed of natural and/or synthetic fibers. The body side liner can be composed of a substantially hydrophobic material, and the hydrophobic material can, optionally, be treated with a surfactant or otherwise processed to impart a desired level of wettability and hydrophilicity. For example, the material can be surface treated with about 0.45 weight percent of a surfactant mixture comprising Ahcovel N-62 from Hodgson Textile Chemicals of Mount Holly, N.C. U.S.A. and Glucopan 220UP from Henkel Corporation of Ambler, Pa. in an active ratio of 3:1. The surfactant can be applied by any conventional means, such as spraying, printing, brush coating or the like. The surfactant can be applied to the entire body side liner 42 or can be selectively applied to particular sections of the body side liner, such as the medial section along the longitudinal centerline.

A suitable liquid permeable body side liner 42 is a nonwoven bicomponent web having a basis weight of about 27 gsm. The nonwoven bicomponent can be a spunbond bicomponent web, or a bonded carded bicomponent web. Suitable bicomponent staple fibers include a polyethylene/polypropylene bicomponent fiber available from CHISSO Corporation, Osaka, Japan. In this particular bicomponent fiber, the polypropylene forms the core and the polyethylene forms the sheath of the fiber. Other fiber orientations are possible, such as multi-lobe, side-by-side, end-to-end, or the like.

The absorbent assembly 44 (FIG. 3) is positioned between the outer cover 40 and the body side liner 42, which components can be joined together by any suitable means such as adhesives, ultrasonic bonds, thermal bonds, or the like. The absorbent assembly 44 can be any structure which is generally compressible, conformable, non-irritating to the child's skin, and capable of absorbing and retaining liquids and certain body wastes. The absorbent assembly 44 can be manufactured in a wide variety of sizes and shapes, and from a wide variety of liquid absorbent materials commonly used in the art. For example, the absorbent assembly 44 can suitably comprise a matrix of hydrophilic fibers, such as a web of cellulose fluff, mixed with particles of a high-absorbency material commonly known as superabsorbent material. In a particular embodiment, the absorbent assembly 44 comprises a matrix of cellulose fluff, such as wood pulp fluff, and superabsorbent hydrogel-forming particles. The wood pulp fluff can be exchanged with synthetic, polymeric, meltblown fibers or short cut homofilament or bicomponent synthetic fibers and natural fibers. The superabsorbent particles can be substantially homogeneously mixed with the hydrophilic fibers or can be nonuniformly mixed. The fluff and superabsorbent particles can also be selectively placed into desired zones of the absorbent assembly 44 to better contain and absorb body exudates. The concentration of the superabsorbent particles can also vary through the thickness of the absorbent assembly 44. Alternatively, the absorbent assembly 44 can comprise a laminate of fibrous webs and superabsorbent material or other suitable means of maintaining a superabsorbent material in a localized area.

Suitable superabsorbent materials can be selected from natural, synthetic, and modified natural polymers and materials. The superabsorbent materials can be inorganic materials, such as silica gels, or organic compounds, such as cross-linked polymers, for example, sodium neutralized polyacrylic acid. Suitable superabsorbent materials are available from various commercial vendors, such as Dow Chemical Company located in Midland, Mich. U.S.A., and Stockhausen GmbH & Co. KG, D-47805 Krefeld, Federal Republic of Germany. Typically, a superabsorbent material is capable of absorbing at least about 15 times its weight in water, and desirably is capable of absorbing more than about 25 times its weight in water.

In one embodiment, the absorbent assembly 44 is generally rectangular in shape, and comprises a blend of wood pulp fluff and superabsorbent material. One preferred type of pulp is identified with the trade designation CR1654, available from U.S. Alliance, Childersburg, Ala. U.S.A., and is a bleached, highly absorbent sulfate wood pulp containing primarily soft wood fibers and about 16 percent hardwood fibers. As a general rule, the superabsorbent material is present in the absorbent assembly 44 in an amount of from about 5 to about 90 weight percent based on total weight of the absorbent assembly. The absorbent assembly 44 suitably has a density within the range of about 0.10 to about 0.35 grams per cubic centimeter. The absorbent assembly 44 may or may not be wrapped or encompassed by a suitable tissue wrap that may help maintain the integrity and/or shape of the absorbent assembly.

The absorbent body 32 can also incorporate other materials that are designed primarily to receive, temporarily store, and/or transport liquid along the mutually facing surface with absorbent assembly 44, thereby maximizing the absorbent capacity of the absorbent assembly. One suitable material is referred to as a surge layer (not shown) and comprises a material having a basis weight of about 50 to about 120 grams per square meter, and comprising a through-air-bonded-carded web of a homogenous blend of 60 percent 3 denier type T-256 bicomponent fiber comprising a polyester core/polyethylene sheath and 40 percent 6 denier type T-295 polyester fiber, both commercially available from Kosa Corporation of Salisbury, N.C. U.S.A.

As noted previously, the illustrated training pant 20 has front and back side panels 34 and 134 disposed on each side of the absorbent body 32. These transversely opposed front side panels 34 and transversely opposed back side panels 134 can be permanently bonded along attachment lines 66 to the composite structure 33 of the absorbent body 32 in the respective front and back waist regions 22 and 24. More particularly, as shown best in FIGS. 2 and 3, the front side panels 34 can be permanently bonded to and extend transversely beyond the linear side edges 47 of the composite structure 33 in the front waist region 22, and the back side panels 134 can be permanently bonded to and extend transversely beyond the linear side edges of the composite structure in the back waist region 24. The side panels 34 and 134 may be attached using attachment means known to those skilled in the art such as adhesive, thermal or ultrasonic bonding. Alternatively, the side panels 34 and 134 can be formed as a portion of a component of the composite structure 33. For example, the side panels can comprise a generally wider portion of the outer cover, the body side liner, and/or another component of the absorbent body.

The side panels 34 and 134 preferably have elastic properties with sufficient extensibility to allow the wearer to pull the product up without having to open the fasteners on the pant. The side panels 34 and 134 also preferably provide sufficient retraction tension at extensions normally seen during wear to ensure good fit during wear without adjusting the fastener position. If the outer cover 40, as described above, comprises an elastic material, the side panels 34 and 134 may require less extensibility. Alternately, the pant may have an all-over stretch material across the entire width of the pant, comprising the outer cover 40 and side panels 34 and 134 as a single material component. The extension requirements of the side panels 34 and 134 are determined by the desired fit range for the product and the interaction with extension of other components, e.g., outer cover 40.

The illustrated side panels 34 and 134 each define a distal edge 68 that is spaced from the attachment line 66, a leg end edge 70 disposed toward the longitudinal center of the training pant 20, and a waist end edge 72 disposed toward a longitudinal end of the training pant. The leg end edge 70 and waist end edge 72 extend from the side edges 47 of the composite structure 33 to the distal edges 68. The leg end edges 70 of the side panels 34 and 134 form part of the side edges 36 of the absorbent body 32. In the back waist region 24, the leg end edges 70 are desirably although not necessarily curved and/or angled relative to the transverse axis 49 to provide greater coverage toward the back of the pant as compared to the front of the pant. The waist end edges 72 are desirably parallel to the transverse axis 49. The waist end edges 72 of the front side panels 34 form part of the front waist edge 38 of the absorbent body 32, and the waist end edges 72 of the back side panels 134 form part of the back waist edge 39 of the absorbent body.

In particular embodiments for improved fit and appearance, the side panels 34 and 134 desirably have an average length dimension measured parallel to the longitudinal axis 48 that is about 20 percent or greater, and particularly about 25 percent or greater, of the overall length dimension of the absorbent article, also measured parallel to the longitudinal axis 48. For example, in training pants having an overall length dimension of about 54 centimeters, the side panels 34 and 134 desirably have an average length dimension of about 10 centimeters or greater, such as about 15 centimeters. While each of the side panels 34 and 134 extend from the waist opening 50 to one of the leg openings 52, the back side panels 134 have a continually decreasing length dimension moving from the attachment line 66 to the distal edge 68, as is best shown in FIGS. 2 and 3.

Each of the side panels 34 and 134 can include one or more individual, distinct pieces of material. In particular embodiments, for example, each side panel 34 and 134 can include first and second side panel portions that are joined at a seam, or can include a single piece of material which is folded over upon itself (not shown). The side panels 34 and 134 desirably although not necessarily comprise an elastic material capable of stretching in a direction generally parallel to the transverse axis 49 of the training pant 20. Suitable elastic materials, as well as one process of incorporating elastic side panels into a training pant, are described in the following U.S. Pat. No. 4,940,464 issued Jul. 10, 1990 to Van Gompel et al.; U.S. Pat. No. 5,224,405 issued Jul. 6, 1993 to Pohjola; U.S. Pat. No. 5,104,116 issued Apr. 14, 1992 to Pohjola; and U.S. Pat. No. 5,046,272 issued Sep. 10, 1991 to Vogt et al.; all of which are incorporated herein by reference. In particular embodiments, the elastic material comprises a stretch-thermal laminate, a neck-bonded laminate, a reversibly necked laminate, or a stretch-bonded laminate material. Methods of making such materials are well known to those skilled in the art and described in U.S. Pat. No. 4,663,220 issued May 5, 1987 to Wisneski et al.; U.S. Pat. No. 5,226,992 issued Jul. 13, 1993 to Morman; and European Patent Application No. EP 0 217 032 published on Apr. 8, 1987 in the names of Taylor et al.; all of which are incorporated herein by reference. Alternatively, the side panel material may comprise other woven or nonwoven materials, such as those described above as being suitable for the outer cover 40 or body side liner 42; mechanically prestrained materials; or extensible but inelastic materials.

In particular embodiments, one or more of the side panels 34 and 134 can be formed of retractive materials. For example, the side panels 34 and 134 can be formed of an elastomeric material that is adapted to retract upon activation by a source of heat, such as disclosed in U.S. Pat. No. 4,640,726.

The illustrated training pant 20 includes a fastening system 80 for refastenably securing the training pant about the waist of the wearer. The illustrated fastening system 80 includes first fastening components 82 and 83 that are adapted to refastenably connect to mating second fastening components 84 and 85. In one embodiment, one surface of each of the first fastening components 82 and 83 comprises a plurality of engaging elements that project from that surface. The engaging elements of the first fastening components 82 and 83 are adapted to repeatedly engage and disengage engaging elements of the second fastening components 84 and 85.

In one particular embodiment, the first fastening components 82 and 83 each comprise hook type fasteners and the second fastening components 84 and 85 each comprise complementary fasteners formed of a multi-directional stretchable nonwoven loop material. In another particular embodiment, the first fastening components 82 and 83 each comprise fasteners formed of a multi-directional stretchable nonwoven loop material and the second fastening components 84 and 85 each comprise complementary hook type fasteners. Although the illustrated embodiments show the back waist region 24 overlapping the front waist region 22, which is convenient, the training pant 20 can also be configured so that the front waist region overlaps the back waist region.

In alternative embodiments contemplated by this invention, fasteners 82-85 can be located anywhere over the front or back regions 22 and 24 of the pant. The fasteners 82-85 can be integral to any of the materials on the pant in the front or back regions 22 and 24. The fasteners can be integral to the entire outer cover of the pant (e.g. in a one piece outer cover product) or integral to the entire liner in the pant. The fasteners can be integral to panels 34 and/or 134.

Hook type fasteners typically comprise a fabric or material having a base or backing structure and a plurality of hook members extending upwardly from at least one surface of the backing structure. The hook material advantageously comprises a resilient material to minimize unintentional disengagement of the fastener components as a result of the hook material becoming deformed and catching on clothing or other items. The term “resilient” as used herein refers to an interlocking material having a predetermined shape and the property of the interlocking material to resume the predetermined shape after being engaged and disengaged from a mating, complementary interlocking material. Suitable hook material can be molded or extruded of nylon, polypropylene or another suitable material. Suitable single-sided hook materials for the fastening components 82-85 are available from commercial vendors such as Velcro Industries B. V., Amsterdam, Netherlands or affiliates thereof, and are identified as Velcro HTH-829 with a uni-directional hook pattern and having a thickness of about 0.9 millimeters (35 mils) and HTH-851 with a unidirectional hook pattern and having a thickness of about 0.5 millimeters (20 mils); and Minnesota Mining & Manufacturing Co., St. Paul, Minn. U.S.A., including specific materials identified as CS-600.

In accordance with the present invention, the loop type fastener is preferably made of a multi-directional stretchable material, such as a gathered nonwoven facing bonded to an elastic substrate so that the composite is extensible and provides retraction tension over a suitable range of extensions. With particular reference to FIG. 3, the first fastening components 82 and 83 are desirably although not necessarily disposed on the inner surface 28 of the training pant 20 in the back waist region 24. The first fastening components 82 and 83 are desirably positioned along the distal edges 68 of the back side panels 134, and abutting or adjacent to the waist end edge 72. In certain embodiments, for example, the first fastening components 82 and 83 can be located within about 2 centimeters, and more particularly within about 1 centimeter, of the distal edges 68, the waist end edges 72, and the leg end edges 70.

With particular reference to FIG. 2, the second fastening components 84 and 85 are desirably although not necessarily disposed on the outer surface 30 of the training pant 20 in the front waist region 22. The second fastening components 84 and 85 are sized to receive the first fastening components 82 and 83 and are desirably positioned along the distal edges 68 of the front side panels 34, and abutting or adjacent to the waist end edge 72. In certain embodiments, for example, the second fastening components 84 and 85 can be located within about 2 centimeters, and more particularly within about 1 centimeter, of the distal edges 68, the waist end edges 72, and the leg end edges 70. Where the first fastening components 82 and 83 comprise loop type fasteners disposed on the inner surface 28 and the second fastening components 84 and 85 comprise hook type fasteners disposed on the outer surface 30, the first fastening components can be sized larger than the second fastening components to ensure coverage of the rigid, outwardly-directed hooks. The loop fastening components can be integral with the side panels or adhered to the side panels 34 and 134 by any means known to those skilled in the art such as adhesive bonds, sonic bonds or thermal bonds. The extensible loop fastening components can be bonded to components of the body 32 in a manner that retains the extension and retraction characteristics of the loop fastening components.

The fastening components are desirably rectangular, although they may alternatively be square, round, oval, curved or otherwise non-rectangular in shape. In particular embodiments, each of the fastening components 82-85 defines a length dimension aligned generally parallel with the longitudinal axis 48 of the training pant 20 and a width dimension aligned generally parallel with the transverse axis 49 of the training pant. For a child of about 9 to about 15 kilograms (20-33 pounds), for example, the length dimension of the fastening components is desirably from about 5 to about 13 centimeters, such as about 10 centimeters, and the width dimension is desirably from about 0.5 to about 3 centimeters, such as about 1 centimeter. With particular embodiments, the fastening components can have a length-to-width ratio of about 2 or greater, such as about 2 to about 25, and particularly about 5 or greater, such as about 5 to about 8. For other embodiments such as for adult products, it may be desirable for one or more of the fastening components to comprise a plurality of relatively smaller fastening elements. In that case, a fastening component or individual fastening elements may have an even smaller length-to-width ratio, for example, of about 2 or less, and even about 1 or less.

When the fastening components 82-85 are releasably engaged, the side edges 36 of the absorbent body 32 in the crotch region 26 define the leg openings 52, the waist edges 38 and 39 of the absorbent body, including the waist end edges 72 of the side panels, define the waist opening 50, and the waist regions 22 and 24 jointly define a waistband 75 and hip section 77. For improved formation of the leg openings 52, it can be desirable in some embodiments for the front side panels 34 to be longitudinally spaced from the back side panels 134 (see FIGS. 2 and 3). For example, the front side panels 34 can be longitudinally spaced from the back side panels 134 by a distance equal to about 20 percent or greater, particularly from about 20 to about 60 percent, and more particularly from about 35 to about 50 percent, of the overall length dimension of the absorbent article.

When connected, the fastening components 82-85 form refastenable seams 88 (FIG. 1) that desirably although not necessarily extend substantially the entire distance between the waist opening 50 and the leg openings 52. More specifically, the refastenable seams 88 can cover about 80 to 100 percent, and particularly about 90 to about 98 percent, of the distance between the waist opening 50 and each leg opening 52, which distance is measured parallel to the longitudinal axis 48. To construct the seams 88 to extend substantially the entire distance between the waist and leg openings 50 and 52, the fastening components 82-85 can be formed to cover about 80 to 100 percent, and more particularly about 90 to about 98 percent, of the distance between the waist end edge 70 and the leg end edge 72 of the side panels 34 and 134. In other embodiments, the fastening components can comprise a plurality of smaller fastening elements covering a smaller portion of the distance between the waist opening 50 and the leg openings 52, for example, about 20 to about 70 percent, but spaced apart to span a larger percentage of the distance between the waist opening and the leg openings.

It is also contemplated that the fastening components 82-85 may be incorporated as integral portions of the pant rather than separate components applied during manufacture. If the fastening components 82 and 83, are a single component and are integral to the pant in the front region 22, for example, the size and the shape of the fastening component is directly equal to the size and shape of that region. If the fastening components 82-85 are integral parts of side panels 34 and/or 134, for another example, the fastening components are the same size and shape as the side panels 34 and/or 134.

For the refastenable seams 88 to be located at the sides of the wearer, it can be particularly desirable for the transverse distance between the first fastening components 82 and 83 to be substantially equal to the transverse distance between the second fastening components 84 and 85. The transverse distance between a set of fasteners is the distance measured parallel to the transverse axis 49 between the longitudinal centerlines of the fasteners, measured with the side panels 34 and 134 in their relaxed, or non-extended, condition. In an alternative embodiment, the training pant 20 includes only a single second fastening component disposed in the front waist region 22 for refastenably connecting the first fastening components 82 and 83 (not shown).

In a further alternative embodiment illustrated in FIGS. 4 and 5, one or both of the fastening components can comprise integral portions of the waist regions. For instance, the front and back side panels 34 and 134 can function as fastening components in that they can comprise a material that is releasably engageable with complementary fastening components disposed in the opposite waist region. As illustrated in FIGS. 4 and 5, the side panels 134 are made completely of multi-directional stretchable nonwoven loop material. Alternatively, these side panels could be made of multi-directional stretchable nonwoven loop material only at their outer edges where they will engage the hook material, and the remainder of the side panels can be made of some other, preferably extensible, material and joined along abutting edges thereof.

This invention uses a multi-directional stretchable loop material to provide fiber loops accessible to the hook material and having sufficient integrity to withstand engagement. It is believed that the stretch in the loop material allows flexibility such that as it is stretched during use, only some of the points of engagement between the hooks and loops are separated when the product is stressed, and then some of the hooks are able to reattach to a different spot in the loop material as it contracts. This can reduce the “pop opens” (abrupt disengagement of the fasteners) over conventional hook-and-loop fasteners, which tend to separate all at once. The fastening system could also employ stretchable or elastic hook material so that the hook material would stretch with the loop material, providing additional flexibility and partial disengagement before actual failure.

The multi-directional stretchable loop material can be formed by various methods, including those specifically described below and combinations and permutations thereof. For instance, the multi-directional stretchable loop material can be formed by elongating an elastomeric substrate in multiple directions and bonding the stretched elastomeric substrate to a nonwoven web. The elastomeric substrate can for example be stretched in both a machine direction and a cross machine direction. The nonwoven web can be ungathered, gathered in one direction, or gathered in multiple directions. In particular embodiments, the multi-directional stretchable loop material can comprise a generally ungathered nonwoven web stretch-bonded to a multi-directional stretch elastomeric material. Additionally, the multi-directional stretchable loop material can be formed by pregathering a nonwoven web and bonding the pregathered nonwoven to an elastomeric substrate having elongation characteristics in a direction other than or besides the direction of gathering. The nonwoven web can be gathered by any suitable means, such as creping, necking, use of retractive materials, or the like. Suitable retractive materials for gathering the nonwoven web or composite can comprise any material adapted to retract upon activation, whether immediately upon activation or subsequently thereto. The retractive material can comprise elastomeric or nonelastomeric materials. Suitable nonelastomeric retractive materials can comprise without limitation heat shrinkable polyethylene films or the like, and laminates thereof. Suitable elastomeric retractive materials can comprise without limitation LYCRA® materials, elastomeric materials including latex rubber or synthetic urethanes, or the like, and laminates thereof. In particular embodiments, the retractive material can comprise an elastomeric material having an unstable state relative to some other stable and elastic state. In such embodiments, the retractive material can but need not have elastomeric properties in the unstable state. Other exemplary retractive materials are described in PCT publication WO 01/87206 dated Nov. 22, 2001, which is incorporated herein by reference.

In one embodiment, the loop material is a neck-stretched elastic laminate material made by (1) elongating a nonwoven facing in the machine direction while allowing it to neck down in the cross direction, and (2) laminating the resulting necked facing to an elastic substrate while it is elongated in the machine direction. The necking of the facing provides the ability for the material to be extended in the cross direction to about its pre-necked width. This also orients the fibers in the machine direction, which provides an increase in fiber loops available in the cross direction of the material. The stretch-bonding laminating process takes the necked facings and attaches them to a stretched elastic material. The stretched elastic then gathers the nonwoven facing in the machine direction when the stretching force is released. This gathering then creates a higher density of fibers in the machine direction. This sequence of process steps takes a flat, two-dimensional facing and forms a multi-directional stretchable nonwoven loop material.

In another embodiment, the loop material is a creped-stretched elastic laminate material made by (1) creping a nonwoven facing in the machine direction, and (2) laminating the resulting creped facing to an elastic substrate while the elastic substrate is elongated in the cross direction. The creping of the facing provides the ability for the material to be extended in the machine direction to about its pre-creped length. The stretch-bonding laminating process takes the creped facings and attaches them to a stretched elastic material. The stretched elastic then gathers the nonwoven facing in the cross direction when the stretching force is released. This gathering then creates a higher density of fibers in the cross direction. This sequence of process steps takes a flat, two-dimensional facing and forms a multi-directional stretchable loop material.

One embodiment of the loop material utilized in the fastening system of the present invention can be manufactured as set forth in U.S. Pat. No. 5,116,662, incorporated herein by reference thereto. For example, the neckable material is a nonwoven web of fibers, which should be joined by interfiber bonding to form a coherent web structure which is able to withstand necking. Interfiber bonding may be produced by entanglement between individual meltblown fibers. The fiber entangling is inherent in the meltblown process but may be generated or increased by processes such as, for example, hydraulic entangling or needlepunching. Alternatively and/or additionally thermal bonding or a bonding agent may be used to increase the desired coherence of the web structure.

The gathered nonwoven facing can be made by taking a suitable nonwoven material and elongating it in one or more directions, and causing the web to neck or narrow in the direction(s) perpendicular to the direction(s) of elongation. The nonwoven material used to form the gathered nonwoven facing can be made in accordance with the teachings of U.S. Pat. No. 4,965,122 incorporated herein by reference thereto. Suitable nonwoven material may be formed by known nonwoven processes, such as, for example, meltblowing processes, spunbonding processes or bonded carded web. If the nonwoven material is a web of meltblown fibers, it may include meltblown microfibers.

The gathering of the nonwoven facing can be accomplished by neck-stretching of the material. Any material that can be extended upon application of a force to its pre-necked dimensions is suitable for neck-stretching. A necked material can be made into a neck-bonded laminate as taught in U.S. Pat. No. 4,981,747. A necked material may also be treated while necked to instill a memory into the material to cause the material to retract from its extension as taught in U.S. Pat. No. 4,965,122. One such method of treatment is the application of heat. Certain polymers such as, for example, polyolefins, polyesters and polyamides may be heat treated under suitable conditions to impart such memory. Exemplary polyolefins include one or more of polyethylene, polypropylene, polybutene, ethylene copolymers, propylene copolymers and butene copolymers. Polypropylenes that have been found useful include, for example, polypropylene available from the Himont Corporation under the trade designation PC-973, polypropylene available from the Exxon Chemical Company under the trade designation Exxon 3445, and polypropylene available from the Shell Chemical Company under the trade designation DX 5A09. Chemical characteristics of these materials are available from their respective manufacturers.

The nonwoven material used to form the gathered nonwoven facing could be a multilayer material having, for example, at least one layer of spunbonded web joined to at least one layer of meltblown web, bonded carded web or other suitable material. For example, the neckable material may be a multilayer material having a first layer of spunbonded polypropylene having a basis weight from about 0.2 to about 8 ounces per square yard (osy), a layer of meltblown polypropylene having a basis weight from about 0.2 to about 4 osy, and a second layer of spunbonded polypropylene having a basis weight of about 0.2 to about 8 osy. Alternatively, the nonwoven material used to form the gathered nonwoven facing may be a single layer of material such as, for example, a spunbonded web having a basis weight of from about 0.2 to about 10 osy or a meltblown web having a basis weight of from about 0.2 to about 8 osy.

The nonwoven material used to form the gathered nonwoven facing may also be a composite material made of a mixture of two or more different fibers or a mixture of fibers and particulates. Such mixtures may be formed by adding fibers and/or particulates to a gas stream in which meltblown fibers are carried so that an intimate entangled commingling of meltblown fibers and other materials, e.g., wood pulp, staple fibers or particulates such as, for example, super-absorbent materials occurs prior to collection of the fibers upon a collecting device to form a coherent web of randomly dispersed meltblown fibers and other materials such as disclosed in U.S. Pat. No. 4,100,324, the disclosure of which is hereby incorporated by reference.

The relation between the original dimensions of the nonwoven material used to form the gathered nonwoven facing to its dimensions after gathering determines the extension limits of the gathered material. For example, if it is desired to prepare a necked material that can be readily extended to a 150 percent elongation (i.e., 250 percent of its necked width) a material having a width “A” such as, for example, 250 cm, is tensioned so that it necks down to a width “B” of about 100 cm for a percent neck or percent neckdown of about 60 percent. The resulting necked material has a width “B” of about 100 cm and is readily extensible to at least the original 250 cm dimension “A” of the material for an elongation or percent stretch of about 150 percent.

The elastic substrate may be made from any material which may be manufactured in sheet or web form. Generally, any suitable elastomeric fiber forming resins or blends containing the same may be utilized. The elastic substrate can comprise elastomeric fibers, threads, filaments, and/or strands, nonwoven webs of elastomeric fibers, threads, filaments, and/or strands, elastomeric films, or the like. Useful elastic substrates may have basis weights ranging from about 5 gsm (grams per square meter) to about 300 gsm, for example, from about 5 gsm to about 150 gsm.

For example, the elastic substrate may be made from block copolymers having the general formula A-B-A′ where A and A′ are each a thermoplastic polymer endblock which contains a styrenic moiety such as a poly (vinyl arene) and where B is an elastomeric polymer midblock such as a conjugated diene or a lower alkene polymer. The elastic substrate may be formed from, for example, (polystyrene/poly(ethylene-butylene)/polystyrene) block copolymers available from the Shell Chemical Company under the trademark KRATON G. One such block copolymer may be, for example, KRATON™ G-1657.

Other exemplary elastomeric materials which may be used to form elastic substrate include polyurethane elastomeric materials such as, for example, those available under the trademark ESTANE from B. F. Goodrich & Co., polyamide elastomeric materials such as, for example, those available under the trademark PEBAX from the Rilsan Company, and polyester elastomeric materials such as, for example, those available under the trade designation Hytrel from E. I. DuPont De Nemours & Company. Formation of elastic substrates from polyester elastic materials is disclosed in, for example, U.S. Pat. No. 4,741,949 to Morman et al., hereby incorporated by reference. Elastic substrate may also be formed from elastic copolymers of ethylene and at least one vinyl monomer such as, for example, vinyl acetates, unsaturated aliphatic monocarboxylic acids, and esters of such monocarboxylic acids. The elastic copolymers and formation of elastic substrates from those elastic copolymers are disclosed in, for example, U.S. Pat. No. 4,803,117.

Processing aids may be added to the elastomeric polymer. For example, a polyolefin may be blended with the elastomeric polymer (e.g., the A-B-A elastomeric block copolymer) to improve the processability of the composition. The polyolefin must be one which, when so blended and subjected to an appropriate combination of elevated pressure and elevated temperature conditions, is extrudable, in blended form, with the elastomeric polymer. Useful blending polyolefin materials include, for example, polyethylene, polypropylene and polybutene, including ethylene copolymers, propylene copolymers and butene copolymers. A particularly useful polyethylene may be obtained from the U.S.I. Chemical Company under the trade designation Petrothene NA 601 (also referred to herein as PE NA 601 or polyethylene NA 601). Two or more of the polyolefins may be utilized. Extrudable blends of elastomeric polymers and polyolefins are disclosed in, for example, U.S. Pat. No. 4,663,220 to Wisneski et al., hereby incorporated by reference. The elastic substrate may also be a pressure sensitive elastomeric adhesive substrate.

The elastic substrate may also be a multilayer material in that it may include two or more individual coherent webs and/or films. Additionally, the elastic substrate may be a multilayer material in which one or more of the layers contain a mixture of elastic and inelastic fibers or particulates. An example of the latter type of elastic web, reference is made to U.S. Pat. No. 4,209,563, incorporated herein by reference, in which elastomeric and non-elastomeric fibers are commingled to form a single coherent web of randomly dispersed fibers. Another example of such an elastic composite web would be one made by a technique such as disclosed in previously referenced U.S. Pat. No. 4,741,949. That patent discloses an elastic nonwoven material which includes a mixture of meltblown thermoplastic fibers and other materials. The fibers and other materials are combined in the gas stream in which the meltblown fibers are borne so that an intimate entangled commingling of meltblown fibers and other materials, e.g., wood pulp, staple fibers or particulates such as, for example, hydrocolloid (hydrogel) particulates commonly referred to as super-absorbents occurs prior to collection of the fibers upon a collecting device to form a coherent web of randomly dispersed fibers.

The nonwoven facing materials may be joined to one or both sides of the tensioned elastic substrate in at least three places by any suitable means such as, for example, adhesives, hydraulic entangling, thermal bonding or ultrasonic welding. Thermal and/or ultrasonic joining techniques are believed to soften at least portions of at least one of the materials, usually the elastic substrate, because the elastomeric materials used for forming the elastic substrate have a lower softening point than the components of the facing material. Joining may be produced by applying heat and/or pressure to the overlaid tensioned elastic substrate and the tensioned, facing material by heating these portions (or the overlaid layer) to at least the softening temperature of the material with the lowest softening temperature to form a reasonably strong and permanent bond between the re-solidified softened portions of the elastic substrate and the facing material.

The gathered facing material should be joined to the tensioned elastic substrate in at least three locations which are arranged so that upon release of the tensioning force on the elastic substrate, puckers or gathers form in the facing material between at least two of the locations. The three or more locations should be arranged in a nonlinear configuration to form for example, a triangular or polygonal pattern of locations where the facing material is joined to the elastic substrate.

With regard to thermal bonding, one skilled in the art will appreciate that the temperature to which the materials, or at least the bond sites thereof, are heated for heat-bonding will depend not only on the temperature of the heated roll(s) or other heat sources but on the residence time of the materials on the heated surfaces, the basis weights of the materials and their specific heats and thermal conductivities. Hence, the processing conditions necessary to achieve satisfactory bonding can be readily determined for a given combination of materials.

To the extent that the facing material exhibits some resistance to being gathered, the elastic substrate will be unable to fully recover to its unstretched dimension once it is joined to the facing material. This requires that the distance that the elastic substrate is elongated when it is joined to the facing material be greater than the desired stretch of the elastic composite material in any direction that the facing material resists gathering. For example, if it is desired to prepare an elastic composite material that can be elongated about 100 percent in the machine direction (i.e., stretched to a length that is about 200 percent of its initial relaxed length), a 100 cm length of elastic web may be stretched in the machine direction to a length of, for example, 220 cm (120 percent elongation) and bonded at least at three locations (arranged in spaced-apart non-linear configuration) to a 220 cm length of necked material. The bonded composite elastic material is then allowed to relax, and even if the elastic substrate is capable of recovering to its original 100 cm length, the necked material bonded thereto will inhibit full recovery and the composite may relax to a length of say, 110 cm. Puckers or gathers will form in the necked material between at least two of the bond points. The resulting 110 cm length of composite material is stretchable in the machine direction to its 220 cm length to provide a composite material that can be elongated about 100 percent in the machine direction (i.e., stretched to a length that is about 200 percent of its initial relaxed length). The initial length of the necked material limits, in this hypothetical example, the attainable machine direction elongation of the composite material because the necked material would act as a “stop” to prevent further or excessive stretching of the elastic substrate in the machine direction under the effect of stretching forces which are less than the failure strength of the necked, gathered material.

The relation between the original dimensions of the facing material to its dimensions after gathering determines the approximate limits of stretch of the composite elastic material in the direction of gathering, typically the cross-machine direction. For example, if it is desired to prepare a composite elastic material that can be elongated about 150 percent (i.e., stretched to a length that is about 250 percent of its initial relaxed length) in a direction generally parallel to the narrowing of a necked facing material (i.e., the cross direction) and that can be elongated about 100 percent (i.e., stretched to a length that is about 200 percent of its initial relaxed length) in the perpendicular direction (i.e., machine direction), a width of facing material having a width “A” such as, for example, 250 cm, is tensioned so that it necks down to a narrower width “B” of about 100 cm. In this example, the necked material is joined to an elastic substrate which is about the same width “B” as the necked material and which is stretchable in the cross direction at least to about the same width “A” as the original pre-necked dimension of the necked material. For example, the elastic substrate may be approximately 100 cm and be stretchable to at least a width of 250 cm. The necked material and the elastic substrate are overlaid and joined at least at three spaced apart locations arranged in a nonlinear configuration while the elastic substrate is maintained at a machine direction elongation of about 120 percent (i.e., stretched about 220 percent of its initial relaxed machine direction dimension) because, as previously noted, the facing material tends to prevent the elastic substrate from retracting fully to its original length in the elongation direction.

The joined layers are allowed to relax, causing puckers or gathers to form in the necked material between at least two of the bond locations. The resulting composite elastic material has a width “B” of about 100 cm and is stretchable to at least the original 250 cm width “A” of the facing material for an elongation of about 150 percent (i.e., stretchable to about 250 percent of its initial necked width “B”). The composite elastic material is adapted to recover to its initial width “B” of about 100 cm because recovery of the elastic substrate to its initial width “B” causes the attached facing material to recover to its necked width “B”. Additionally, the composite elastic material is stretchable to about 100 percent in the machine direction which is the extent that the gathers or puckers in the necked material allow the elastic substrate to elongate in that direction. The distance that the elastic substrate should be capable of stretching in the cross direction before it is joined to the necked material needs only to be as great as the distance that the composite elastic material is desired to stretch in the cross direction. However, as previously noted, the distance that the elastic substrate should be capable of stretching in the machine direction before it is joined to the necked material should be greater than the distance that the composite material is desired to stretch in the machine direction.

The gathers in the facing material may allow the composite elastic material to have stretch and recovery in a range of directions that are not substantially parallel to the elongation direction, for example, in a direction that differs from the elongation direction by about 45 degrees. Similarly, the gathering of the facing material may allow the composite elastic material to have stretch and recovery in a range of directions that are not substantially parallel to the direction of gathering, for example, in a direction that differs from the direction of gathering by about 45 degrees. Because the gathers in the facing material and the direction of elongation of the elastic substrate may be aligned to allow stretch and recovery in generally perpendicular directions, and because the gathers and elongation of the elastic substrate allow stretch and recovery in a range of directions, the composite elastic material may be adapted to have stretch and recovery in substantially all directions along the length and width of the material.

The stretchable loop material can also comprise a mechanically prestrained material. The term “mechanically prestrained” as used herein refers to a material that has undergone localized mechanical stretching to permanently elongate inelastic components of the material. By way of illustration, a composite of an inelastic nonwoven and an elastic substrate can be mechanically prestrained such that the composite is extensible beyond the original limits of the inelastic nonwoven. In particular embodiments, a disposable absorbent pant can incorporate a mechanically prestrained composite comprising a nonwoven facing bonded to an elastic substrate, which can either be untensioned or under tension in one or more directions.

With particular reference again to the embodiment shown in FIG. 3, the front and back side panels 34 and 134 can be provided with fastening components 82-85. Any of the fastening components 82-85 can comprise multi-directional stretchable loop materials of the present invention. If the stretchable loop material is provided as a separate component bonded to the side panel, the stretchable loop material should be attached thereto so that the stretchable loop material remains free to stretch during use of the pants 20. If the side panel is made of a non-stretchable material, this can still be achieved, for example, by making the stretchable loop material an extension forming an outer edge of the side panel. Another method of attachment can be to place the stretchable loop material over the front or back waist region 22 or 24 and bonding only an inner edge of the stretchable loop material to the waist region so transversely outward portions of the loop material are allowed to stretch when a force is placed on the hook and loop engagement interface. The product design options are not limited to stretchable loop materials attached as separate members, however. The stretchable loop materials can be any material on the inside or outside of the product that is made in a fashion that will allow the loop material to stretch when a force is applied to it and allow a hook material to engage in its surface.

The force applied to the hook and loop engagement interface can be in the longitudinal direction 48 of the product, in the transverse direction 49, or in both the longitudinal and transverse directions. The loop material with multi-directional stretch will provide the benefit of reduced in-use product pop-open failures from all directions. This is especially important for the leg area of pants. The leg area is stressed from multiple directions during normal movement of the leg. Most areas of pant-type products are stressed from multiple directions depending on the activity of the wearer.

In one particular embodiment, the back side panels 134 comprise a multi-directional stretchable elastic material that is also a multi-directional stretchable loop material. A hook material 84-85 which may or may not be stretchable, is secured at the outer edge of the front side panels 34. When the hook material contacts the loop material, the loop material is still stretchable in multi-directions. When a force is placed on this fastening system from any direction or in multiple directions the loop material will start to disengage between the hook and loop interface at the edge from which the force is applied. This releasing of the hook from the loop material allows the product to increase in size by the stretch of the elastic in the loop material and thus reduces the force on the system and prevents the pant from opening up any further during use. The hook material thus has a chance to re-engage with the loop material in a new location.

With this stretch capability in the loop material in the direction of the force applied especially in and around the leg area it reduces the need for an engagement system that will withstand high shear loads compared to a system with no stretch capability. The inventors have found that low shear strengths for a stretch loop system of 1500-3900 grams can perform as well as the non-stretch loop systems with shear strengths of 4000-5000 grams or greater. The inventors believe that the study results referenced below, which concern uni-directional stretch loop systems, indicate that multi-directional stretch loop systems having shear strengths of 1500 to 3900 grams would provide acceptable engagement levels in many types of garments. In particular, one study showed that a system with the same hook material attached to a non-stretch loop with average shear strength of 4700 grams performed equally as well with a stretch loop having average shear strength of 2400 grams. Engagement failures with each system used on disposable training pants were both less than 0.6%.

Another study with non-stretch loop material with average shear strength of 4000 grams had unacceptable engagement failure rates at the 1.0% level, while the comparable stretch loop code with average shear strength levels of 2900 grams had less than 0.1% failures.

Another study with non-stretch loop material with average shear strength of 3500 grams had unacceptable engagement failure rates at the 2.7% level.

Yet another study with a stretch loop system with average shear strength of 1800 grams had an acceptable engagement failure rate (qualitative study).

The fastening systems of the present invention desirably provide lower levels of shear strength than conventional non-stretch fastening systems. In particular, the multi-directional stretchable loop material and the hook material of the present fastening systems desirably provide shear strength values of less than 3900 grams in each of two generally perpendicular directions. More particularly, the present fastening systems provide shear strength values in two generally perpendicular directions of about 1500 or more and less than 3900 grams, particularly about 3500 grams or less, more particularly about 3000 grams or less, more particularly about 2900 grams or less, more particularly about 2700 grams or less, more particularly about 2500 grams or less, and still more particularly about 2400 grams or less. The two generally perpendicular directions can but need not be aligned with the longitudinal and transverse axes of the garment.

For purposes of the present invention, shear strength values are determined using the following shear test, which simulates the forces put on a hook and loop system during product use. This test uses a 3 inch (76.2 mm) wide sample of hook material engaged to a 3 inch (76.2 mm) wide sample of loop material and tested first in the transverse direction of the product. The hook and loop material are attached to the same materials that they would be attached to in the product. The sample is prepared by aligning and applying the hook material to the loop material. A weighted roller of 2000 grams is twice rolled over the hook and loop engagement area. The sample is then put in a tensile tester in a mode for testing shear strength. The jaws of the tensile tester start at a spacing of 50 mm. The sample is then pulled apart at a rate of 500 mm per minute. The sample is pulled in the tensile tester until the sample pulls apart. The tensile tester records the peak load obtained during the testing procedure. Testing can be done in any direction of the hook and loop system.

While the mechanical fastening means of the present invention are shown and described herein in connection with children's toilet training pants, it is understood that such fastening means may be incorporated into various other disposable absorbent articles, such as diapers, adult incontinence garments, sanitary napkins and the like, as well as surgical bandages and sponges, without departing from the scope of the present invention.

As various changes could be made in the above constructions and methods, without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

When introducing elements of the present invention or the preferred embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. 

1. A garment for personal wear, comprising: a body having first and second end regions; a mechanical fastening system disposed on the body, the mechanical fastening system comprising: a multi-directional stretchable loop fastening component disposed in the first end region of the body, said loop fastening component comprising a nonwoven loop material secured to an elastomeric substrate, said loop fastening component being extensible during use in first and second substantially perpendicular directions generally within the plane of said loop fastening component and being elastomeric during use in at least one of said first and second directions, and a hook fastening component disposed in the second end region of the garment body and comprising a hook material adapted to refastenably engage the multi-directional stretchable loop fastening component; wherein the loop fastening component and the hook fastening component provide shear strength values of less than 3900 grams in each of said first and second directions.
 2. A disposable absorbent article for personal wear, comprising: a body having first and second end regions and comprising a liquid permeable inner layer, an outer layer in opposed relation with the inner layer, and an absorbent layer disposed between the inner layer and the outer layer; a mechanical fastening system disposed on the body, the mechanical fastening system comprising: a multi-directional stretchable loop fastening component disposed in the first end region of the body, said loop fastening component comprising a nonwoven loop material secured to an elastomeric substrate, said loop fastening component being extensible during use in first and second substantially perpendicular directions generally within the plane of said loop fastening component and being elastomeric during use in at least one of said first and second directions, and a hook fastening component disposed in the second end region of the body and comprising a hook material adapted to refastenably engage the multi-directional stretchable loop fastening component; wherein the multi-directional stretchable loop fastening component and the hook fastening component provide shear strength values of about 1500 to about 3900 grams in each of the first and second directions.
 3. A disposable absorbent article for personal wear, comprising: a body having first and second end regions and comprising a liquid permeable inner layer, an outer layer in opposed relation with the inner layer, and an absorbent layer disposed between the inner layer and the outer layer; a mechanical fastening system disposed on the body, the mechanical fastening system comprising: a multi-directional stretchable loop fastening component disposed in the first end region, said loop fastening component comprising a nonwoven loop material secured to an elastic substrate and being elastomeric during use in first and second substantially perpendicular directions generally within the plane of said loop fastening component, and a hook fastening component disposed in the second end region and comprising a hook material adapted to refastenably engage the multi-directional stretchable loop fastening component; wherein the multi-directional stretchable loop fastening component and the hook fastening component provide shear strength values of about 1500 to about 3500 grams in each of the first and second directions.
 4. The garment of claim 1, wherein the multi-directional stretchable loop fastening component is elastomeric during use in both the first and second directions.
 5. The garment of claim 1, wherein the multi-directional stretchable loop fastening component comprises a nonwoven web stretch bonded to an elastomeric film.
 6. The garment of claim 1, wherein the multi-directional stretchable loop fastening component comprises a mechanically prestrained composite.
 7. The garment of claim 1, wherein the multi-directional stretchable loop fastening component and hook fastening component provide shear strength values of about 3500 grams or less in each of the first and second directions.
 8. The garment of claim 7, wherein the multi-directional stretchable loop fastening component and hook fastening component provide shear strength values of about 3000 grams or less in each of the first and second directions.
 9. The garment of claim 8, wherein the multi-directional stretchable loop fastening component and hook fastening component provide shear strength values of about 2500 grams or less in each of the first and second directions.
 10. The garment of claim 1, wherein the hook fastening component is stretchable.
 11. The disposable absorbent article of claim 2, wherein the multi-directional stretchable loop fastening component and hook fastening component provide shear strength values of about 1500 to about 3500 grams in each of the first and second directions.
 12. The disposable absorbent article of claim 11, wherein the multi-directional stretchable loop fastening component and hook fastening component provide shear strength values of about 1500 to about 3000 grams in each of the first and second directions.
 13. The disposable absorbent article of claim 12, wherein the multi-directional stretchable loop fastening component and hook fastening component provide shear strength values of about 1500 to about 2500 grams in each of the first and second directions.
 14. The disposable absorbent article of claim 2, wherein the multi-directional stretchable loop fastening component comprises a neck-stretched elastic laminate.
 15. The disposable absorbent article of claim 2, wherein the multi-directional stretchable landing member comprises a creped-stretched elastic laminate.
 16. The disposable absorbent article of claim 2, wherein the multi-directional stretchable landing member forms part of the outer layer.
 17. The disposable absorbent article of claim 2, wherein the multi-directional stretchable loop fastening component comprises side panels of the body.
 18. The disposable absorbent article of claim 2, wherein the multi-directional stretchable loop material comprises a nonwoven web stretch bonded to an elastomeric film.
 19. The disposable absorbent article of claim 2, wherein the multi-directional stretchable loop material comprises a mechanically prestrained composite.
 20. The disposable absorbent article of claim 3, wherein the multi-directional stretchable loop fastening component comprises a nonwoven web stretch bonded to an elastomeric film.
 21. The disposable absorbent article of claim 3, wherein the multi-directional stretchable loop material comprises a mechanically prestrained composite.
 22. The disposable absorbent article of claim 3, wherein the multi-directional stretchable loop fastening component and hook fastening component provide shear strength values of about 1500 to about 3000 grams in each of the first and second directions.
 23. The disposable absorbent article of claim 22, wherein the multi-directional stretchable loop fastening component and hook fastening component provide shear strength values of about 1500 to about 2500 grams in each of the first and second directions.
 24. The disposable absorbent article of claim 3, wherein the multi-directional stretchable landing member forms part of the outer layer.
 25. The disposable absorbent article of claim 3, wherein the multi-directional stretchable loop fastening component comprises side panels of the body.
 26. The disposable absorbent article of claim 3, wherein the hook fastening component is stretchable. 